Chatter prediction in flank milling of thin-walled parts considering force-induced deformation

Chatter has been a problem in CNC machining process especially during machining thin-walled components with low stiffness. For accurately predicting chatter stability in machining Ti6Al4V thin-walled components, this paper establishes a chatter prediction method considering of cutting parameters and tool path. The fast chatter prediction method for thin-walled components is based on physical simulation software. Cutting parameters and tool path is achieved through the chatter stability lobes test and finite element simulation. Machining process is simulated by the physical simulation software using generated NC code. This proposed method transforms the NC physical simulation toward the practical methodology for the stability prediction over the multi-pocket structure milling.

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Modelling time-domain vibratory deflection response of thin-walled cantilever workpieces during flank milling

Journal of Manufacturing Processes ◽

10.1016/j.jmapro.2018.05.011 ◽

2018 ◽

Vol 33 ◽

pp. 278-290 ◽

Cited By ~ 2

Author(s):

Pratik Khandagale ◽

Gaurav Bhakar ◽

V. Kartik ◽

Suhas S. Joshi

Keyword(s):

Time Domain ◽

Flank Milling ◽

Thin Walled

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Micro-flank milling forces considering stiffness of thin-walled parts

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-017-1249-2 ◽

2017 ◽

Vol 95 (5-8) ◽

pp. 2767-2782 ◽

Cited By ~ 1

Author(s):

Jie Yi ◽

Xibin Wang ◽

Li Jiao ◽

Mingxin Li ◽

Junfeng Xiang ◽

...

Keyword(s):

Flank Milling ◽

Thin Walled ◽

Milling Forces

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Feed Optimization for Five-Axis Flank Milling Thin-Walled Parts

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.703.150 ◽

2014 ◽

Vol 703 ◽

pp. 150-155

Author(s):

Ming Yong Wang

Keyword(s):

Process Optimization ◽

Sequential Quadratic Programming ◽

Tool Path ◽

Milling Process ◽

Flank Milling ◽

Machining Time ◽

Mechanics Model ◽

Finished Surface ◽

Thin Walled ◽

Five Axis

This paper presents process optimization for the five-axis milling based on the mechanics model explained in Part I. The process is optimized by varying the feed as the tool-workpiece engagements. The linear and angular feedrates are optimized by sequential quadratic programming. Sharp feedrate changes may result in undesired feed-marks on the finished surface. The adopted step is to update the the original CL file with optimized and filtered feedrate commands. The five-axis milling process is simulated in a virtual enviroment, and the resulting feedrate outputs are stored at each position along the tool path. The new feedrate profiles are shown to considerably reduce the machining time while avoiding process faults.

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